Observatory Automation Project Detailed Design Review D il d D i - - PowerPoint PPT Presentation

Observatory Automation Project D il d D i R i Detailed Design Review Electric Dome Drive System y (EDDS)

Steven Bauman Contributors: Sarah Gajadhar, Grant Matsushige, Ivan Look Derrick Salmon Ralph Taroma Larry Ivan Look, Derrick Salmon, Ralph Taroma, Larry Roberts, Casey Elizares, Tyson Arruda, William Cruise, Tom Vermeulen, Jim Thomas, DeeDee Warren, Karun Thanjavur Warren, Karun Thanjavur

Version 1.1 July 9, 2010

Appendix T OAP Dome Drive DDR Presentation T1

Appendix T OAP Dome Drive DDR Presentation T2

Scope Scope

Design solution to replace the hydraulic power unit

and operate the dome drive system with electronically controlled motor units.

Remotely control the system under the guidelines

provided by the OAP project M h ifi i d i f d

Meets the specifications and requirements formed

for the dome drive electrical upgrade. D t il d d i h t th i ti t

Detailed design changes to the existing system,

mechanical interfaces, safety considerations, anticipated costs and estimated manpower anticipated costs and estimated manpower resources.

Appendix T OAP Dome Drive DDR Presentation T3

Hydraulic Hydraulic Hydraulic Hydraulic power unit power unit

Appendix T OAP Dome Drive DDR Presentation T4

Scope Scope

Design solution to replace the hydraulic power unit

and operate the dome drive system with electronically controlled motor units.

Remotely control the system under the guidelines

provided by the OAP project M h ifi i d i f d

Meets the specifications and requirements formed

for the dome drive electrical upgrade. D t il d d i h t th i ti t

Detailed design changes to the existing system,

mechanical interfaces, safety considerations, anticipated costs and estimated manpower anticipated costs and estimated manpower resources.

Appendix T OAP Dome Drive DDR Presentation T5

Requirements

Dome Drive Requirements needed for OAP

• Remotely controlled dome drive operation
• The dome drive must be capable of being operated remotely in a “safe” reliable manner from

Waimea.

• NO possible remote control from Waimea when in manual mode at the summit.
• Remote monitoring and status information
• The electronic drive system shall provide necessary status and system information.
• Phase 2 will provide a status page for motor controller system status and monitoring.
• Manual Control
• The drive system control panel must allow local control of the drive system with the same or

y p y improved safety features.

• Preventative Maintenance
• The dome drive system shall provide access to all serviceable components and minimize the

need for scheduled maintenance.

• Improved Reliability
• The new electronic dome drive system should increase the reliability and minimize repairs.
• Safe Interlocking
• The dome drive system shall provide safety interlocking to prevent unauthorized remote

y p y g p control of the drive system. It shall protect personal and other critical systems when/if other systems shutdown or malfunction

• Lock out of the system for maintenance.

Appendix T OAP Dome Drive DDR Presentation T6

• Modify 5th floor spacer room to

allow for more space around the p motor.

• Alterations will improve

maintenance and repairs in the maintenance and repairs in the future.

Appendix T OAP Dome Drive DDR Presentation T7

Replacement Actuator

Parker Hannifin Pneumatic actuator actuator 122psi

• perating

pressure

Appendix T OAP Dome Drive DDR Presentation T8

Solenoid valve

• 4-way valve
• 1 pressure port, 2

cylinder ports, 1 exhaust port exhaust port

• Built in surge

suppression

• 80% reduction in
• 80% reduction in

power use

• Only draws 2

watts of power

• 100-240/AC or

DC DC

• Rain tight, dust

tight, and Ice resistant resistant.

Appendix T OAP Dome Drive DDR Presentation T9

Proof of concept

The Daycrew assembled and assembled and bench tested a similar two port actuator and solenoid valve with valve with 122psi

• perating

p g pressure to verify and validate the validate the design idea.

Appendix T OAP Dome Drive DDR Presentation T10

Appendix T OAP Dome Drive DDR Presentation T11

Dome Drive Unit Components

Brevini Gear d i b SHP Main shaft assembly SHP wheel assembly reduction box assembly Hydroland Hydraulic motor

Appendix T OAP Dome Drive DDR Presentation T12

New Motors and Adapter

Baldor RPM AC

20HP Exploded adapter kit view 20HP

motor 1750RPM 3PH 3 60HZ Brevini Nema

250TC

Motor adapter fl flange

Appendix T OAP Dome Drive DDR Presentation T13

Appendix T OAP Dome Drive DDR Presentation T14

Appendix T OAP Dome Drive DDR Presentation T15

Appendix T OAP Dome Drive DDR Presentation T16

Appendix T OAP Dome Drive DDR Presentation T17

Motor Integration

1)

Valve off the supply and

6) Drain the gearbox

Drive unit modifications

1)

Valve off the supply and return hydraulic lines

2)

Drain and remove the l f h h d l

6) Drain the gearbox 7) Rotate the gearbox 90˚

with the input shaft up.

lines from the hydraulic motor and cap them.

3)

Remove hardware and

with the input shaft up.

8) Rebolt the gearbox 9) Replace the gearbox oil

3)

the hydraulic motor

4)

Remove hardware and the motor adapter assy

9)

p g

10) Install electric motor to

the new adapter kit

the motor adapter assy.

5)

Unbolt the Gearbox from the SHP main shaft assy.

11) Install the hardware

and motor/adapter on the gearbox the gearbox

Appendix T OAP Dome Drive DDR Presentation T18

Appendix T OAP Dome Drive DDR Presentation T19

Appendix T OAP Dome Drive DDR Presentation T20

Location of Dome Drive cabinet

Cabinet details

• Nema 1 enclosure with fans

and filters. S lf t di bi t ith l

• Self standing cabinet with legs
• r other means of support.
• Wheels or casters incorporated

for transportation. p

• Cabinet fitted with Main

molded case circuit breaker (MCB) door and or side panel disconnect disconnect.

• The cabinet will be located in

front of the wall, the ladders will be relocated.

Appendix T OAP Dome Drive DDR Presentation T21

Dome Drive Motor Controller Cabinet

• Power distribution terminal block for three (3)

branch circuit each with:

• 50 Amp molded case circuit breaker (MCB) for

inverse fault protection (loss of line or line short circuit line when drive is regenerating) .

• Thermostatically controlled drive input contactor

to prevent power up at below -10 deg C .

• 3% Input line reactors
• ZD22H420-EL drive

O

• Output motor load reactors

*Grant will discuss the controls of the system

Appendix T OAP Dome Drive DDR Presentation T22

Heat Mitigation strategy

Heat dissipation estimates

B

Heat dissipation estimates

Motors At Full Speed (3.4HP @ 60˚/min) ~ 95 Watts

Meets requirement criteria, no requirement for iti ti mitigation

Motor Controllers At Full Speed (3.4HP @ 60˚/min) ~

256 Watts

W i diffi l i d Worst case estimate, difficult to estimate due to intermittent operation

__________________________PLAN__________________ A) V t th t t ll h t i t th i it ’

C

• A) Vent the motor controller heat into the visitor’s
• gallery. Sealed room with no other heat sources.
• B) Add a standard ventilation fan above the visitors

t i d t t th i l i t th

C

staircase door to vent the room air volume into the staircase

• C) Add a small Thermatron or Lytron heat exchanger

i th b ildi l l t t th b tt f th using the building glycol system to the bottom of the Baldor cabinet.

Appendix T OAP Dome Drive DDR Presentation T23

Monitoring and Status Information Phase 2

Motor Controller

• Stores data about the

Example status page for monitoring the system

Stores data about the functionality and health of the drive system Th O t t b

g g

The Outputs can be

monitored such as; speed, torque, voltage, current, etc.

Communication Method

• Serial interface communication

(RS232) expansion board (RS232) expansion board

• Feedback information for status

via and RS232 cable and Pearle device device.

Appendix T OAP Dome Drive DDR Presentation T24

Time and resource estimates – Implementation plan

Award P.O. for

Prepare the visitor’s gallery, relocate the

Finalize pneumatic lines and location of the Baldor Cabinet Build Room Modifications Actuator Integration and Test

Baldor package Date: ~7/16/2010

ladders, terminate wiring Date: ~8/5/2010

solenoid valve. Modify the rod clevis brackets Date: ~7/28/2010

Baldor begin design and assembly of cabinet

Develop and/or Install provisions for lifting the gear reduction

Shut off supply and return lines, remove old actuator, modify as needed install new

cabinet Date: ~7/19/2010

box and motor Date: ~8/12/2010

needed install new actuator Date: ~8/4/2010

Review cabinet design, approve for final build and ship

Remove the door casting and/or walls and modify as needed

Test actuator function, run dome with new actuator, install remaining actuators

Date: ~9‐1‐2010

Date: ~8/19/2010

Date: ~8/26/10

*Some tasks can be preformed in parallel.*

Appendix T OAP Dome Drive DDR Presentation T25

Time and resource estimates – Implementation plan

Receive motor and adapter inspect

Modify the PLC panel, cabling from PLC to

Receive Baldor drive unit, transport to Spare motor testing Spare motor controller testing Drive unit integration

adapter, inspect and verify part Date: ~7/21/2010

cabling from PLC to cabinet location Date: ~8/31/2010

p summit, move to 5th floor. Date: ~9/7/2010

Remove spare drive unit from crate and install on stand

Testing of the PLC controls, air actuator, motor bench testing

Install the cabinet, connect power, motor wiring PLC wiring etc

install on stand Date: ~7/21/2010

motor bench testing. Date: ~9/3/2010

wiring, PLC wiring, etc. Date: ~9/14/2010

Remove old hydraulic motor and install new electric motor

Baldor consultant arrives, Integrate first unit with new drive components, test system

Date: ~7/29/2010

Date: ~9/27 to 10/1/10

*Some tasks can be preformed in parallel.*

Appendix T OAP Dome Drive DDR Presentation T26

Resource Days Description Detailed Design Review date: ~ July 15,2010 Integration steps after DDR Hardware, SB LF 1/2 Award the purchase order for the Baldor dome drive system mechanical SB,LF 1/2 Award the purchase order for the Baldor dome drive system Baldor Cabinet Build SB 1 Order Drive unit package-Place P.O. to Kaman and Baldor B ld ill b i d d i h d d i bi i h ll h Hardware, mechanical SB, Baldor 42 Baldor will begin and design the dome drive cabinet with all the components described in the proposal. SB, Daycrew, LR,GM CFHT, Gary Tofanelli of Kaman, Krieg Richards and Bill Colton of Baldor will review the design make changes as needed and sign off or approve Implementation (Integration) , y , , g g g pp the plans for the cabinet build. Baldor/Kaman The cabinet will be assembled, tested, and shipped to CFHT in 4-6 weeks by Baldor/Kaman. Room Modifications Using the footprint of the new electric motor/adapter kit combo determine what amount to remove from the upper door area. SB, Daycrew 5 Hardware, Remove the door casting and/or room walls and modify as needed in the spacer room. Develop and/or install provisions for lifting the 265lb gear reduction box and 290lb motor/adapter combo , mechanical and 290lb motor/adapter combo. Daycrew 1 Find a new location to relocate the ladders located in the 5th floor visitor’s gallery; move them to clear space for the new cabinet.

Appendix T OAP Dome Drive DDR Presentation T27

Actuator Integration and Test 1 Inspect the actuators, clevis brackets, and pivot pins for correct model # and dimensions Test set-up for actuators, verify proof of concept on bench Finalize the pneumatic lines running to each dome drive unit for the actuators 2 Finalize the pneumatic lines running to each dome drive unit for the actuators Finalize the location of the solenoid valve and plumbing on each dome drive frame Modify the four (4) female rod clevis brackets SB, Daycrew, GM Record the position of the proportioning valve on the supply and return side of the actuator and valve off the actuators, record the turns needed to shut off the flow Remove the upper and lower pivot pins on the old hydraulic actuator Implementation (Integration) Hardware, mechanical 3 Remove the actuator from the upper and lower brackets and place the actuator with the hydraulic lines still attached to a secure location will bungee cords Modify the top and bottom brackets of the drive unit frame to accommodate the new pneumatic actuator Install (1) one new Pneumatic Actuators actuator in the old units place, on drive unit #2 Test pneumatic actuator function (up/down), line pressure (loss of air), and check for leaks. Remove air supply and power to actuator. See control of air actuator plan, 7.4.d) Run the dome drive system with (1) one pneumatic actuator in place and monitor operational differences from the hydraulic actuators Verification and validation of the pneumatic actuator replacement 3 Install the remaining pneumatic actuators following the steps discussed above. Cap off the supply and return lines for each actuator and label accordingly. Label the actuators and store, discard, or recycle the units.

Appendix T OAP Dome Drive DDR Presentation T28

Spare motor testing SB, Daycrew, LR 1 Receive spare electric motor and motor adapter kit. Inspect motor adapter kit to verify correct dimensions. I t t t if di i Inspect motor to verify dimensions. Remove the spare dome drive unit from the crate and anchor it to a suitable stand (old cute stand) for test fitting. 2 Remove the hardware and hydraulic motor from the spare drive unit and annotate it with a time stamp, unit #, etc. Implementation (Integration) Hardware, mechanical 2 Remove the hardware and adapter plate from the spare drive unit and annotate it with a time stamp, unit #, etc. Next unbolt the gear reduction box from the main shaft assembly and rotate it 90 degrees so the SB, Daycrew input shaft points up. Drain the old oil from the gearbox, record the amount removed, and recycle. 2 Install a new breather tube or expansion tube and add required amount of oil to the gearbox. Install the electric motor to the new motor adapter kit. 2 Mount the electric motor/adapter kit to the gear reduction box. Manually rotate the gear reduction box output shaft and check for smooth operation.

Appendix T OAP Dome Drive DDR Presentation T29

Spare motor controller wiring LR, Daycrew, SB 2 Install the temp circuit breaker and spare motor controller to an anchored cart or stand in the visitor’s gallery. 1 Layout design for the conduit from the 4th floor to the 5th floor. 460V power 10 Install conduit from the 4th floor electronics to the 5th floor. 10 Pull 1 awg. Electrical wire from the 4th floor to the 5th. Run and hook up 480V power to the temp circuit breaker. Ci it b k i i h k T t i i ti it Implementation (Integration) Electrical LR, Daycrew, SB, Circuit breaker wiring check. Test wiring continuity.

• Test 480V wiring connections from DP4 distribution panel to 5th floor.

Run 480V power from the circuit breaker to the spare motor controller , y , , GM 3 Run 8 gauge temp power conduit and cable to the test stand from the temp motor controller. Wire up the motor on the test stand with 8 gauge power and the feedback cable Wire up the motor on the test stand with 8 gauge power and the feedback cable. Motor controller wiring check. Test wiring continuity.

• Test wiring connections from temp circuit breaker to the motor controller.

Motor wiring Check, Test wiring continuity.

• power and feedback cable from the spare motor controller to spare bench motor.

Appendix T OAP Dome Drive DDR Presentation T30

Spare motor controller testing See section 7 for. implementation plan for the control of the system GM 1 Modify the PLC Panel in the computer room 1 Cabling between computer room PLC and dome drive cabinet location 5th floor. 2 PLC code modification Implementation (Integration) Software and control 4 Integration of the controls 3 Testing of the PLC controls 3 Air actuator testing 4 Motor testing 2 Spare motor controller and spare bench motor testing complete. Awaiting Baldor cabinet for integration. TV, SB,GM 3 PLC communication for status monitoring RS232 to Perle communication for status monitoring Status page design Status/monitoring page test Drive unit motor conduit and wiring Electrical LR Daycrew SB 1 Finalize the layout design (floor plan) for the conduit from the 4th floor to the 5th floor. 460V power 2 Layout design (floor plan) for 2 sets of conduit (1/2” and ¾”) for the motor power and feedback cables. 5 Install 2 sets of conduit (1/2” and ¾”) for the motor power and feedback cables Implementation (Integration) Electrical LR, Daycrew, SB 5 Install 2 sets of conduit (1/2 and ¾ ) for the motor power and feedback cables. 5 Pull 8 gauge wires for motors, i.e. electrical wire from the drive units to the drive cabinet location 1 Motor Wiring Check, Test wiring continuity.

• power and feedback cable from drive units to motor controller cabinet

( g ) Drive cabinet integration Hardware SB,LF 1 Receive Baldor drive unit cabinet at HQ SB,RW 1 Transport the cabinet to the summit. SB, Daycrew 1 Install the cabinet in the 5th floor visitor’s gallery and secure it in place. LR 1 Connect 1awg wiring to the drive unit Test functionality Hardware, Mechanical Electrical LR 1 Connect 1awg wiring to the drive unit. Test functionality LR, Daycrew, SB, GM Motor controller wiring check. Test wiring continuity.

• Test wiring connections from circuit breaker and PLC to the motor controller.

LR, SB, Daycrew 1 Finish motor controller cabinet install and checkout.

Appendix T OAP Dome Drive DDR Presentation T31

Drive unit Integration SB, Daycrew 2 Hydraulic motor retrofit can begins a few days before the cabinet is delivered or once the cabinet is integrated Remove hardware, old hydraulic motor, and adapter kit from drive unit #2. Remove hardware and rotate the Brevini gearbox 90 degrees so the input shaft is up Remove hardware and rotate the Brevini gearbox 90 degrees so the input shaft is up. Assemble the new adapter kit/electric motor combination. Install new assembly to the Brevini gear reduction box on drive unit #2 WC, GM, SB 4 TCS/PLC/cabinet Testing with new electric drive unit #2 SB H d SB, Consultant 1 Motor controller consultant arrives on island (this can occur before the first unit is integrated or after) SB, Daycrew, WC, GM, Consultant 2 Dome drive Consultation Commissioning and Testing-Begin day testing of VFD system. T d i i # 2 d l i l Implementation (Integration) Hardware, Mechanical Electrical Test drive unit # 2 under electric motor control SB, Daycrew 1 Prefer to perform Unit #3 retrofit when F/8 is on telescope Remove old hydraulic motor and adapter kit from drive unit #3 Rotate Brevini gearbox 90 degrees Install new Brevini adapter kit on drive unit #3 Install new Electric motor on drive unit # 3 SB, Daycrew, WC, GM, Consultant 2 Test drive unit # 2 and 3 under electric motor control. New electric drive system Commissioned and ready for nightly operations under two drive unit operations New electric drive system Commissioned and ready for nightly operations-under two drive unit operations temporarily. SB, Daycrew 3 Remove old hydraulic motor and adapter kit from drive unit #1 Rotate Brevini gearbox 90 degrees Install new Brevini adapter kit on drive unit #1 Install new Electric motor on drive unit # 1 Install new Electric motor on drive unit # 1 See section 7 for. implementation plan for the control of the system Software, Electrical SB, GM, WC, Daycrew 5 Test drive unit # 1, 2 and 3 under electric motor control. 1 Manual/automatic system tests 3 Phase 1 Finished- Dome drive system now under electric drive system control.

Appendix T OAP Dome Drive DDR Presentation T32

1 1 Baldor ZD22H420EL drive panel package proposal $43,860.53 $43,860.53 Drive system package, 3X motor controllers and equipment needed to assemble drive cabinet, for more information. Baldor 20HP RPM AC ZDFRPM21204C $3 096 00 $9 288 00 Drive system motors, 3X motors. 1 Master and 2 Slaves, for more Equipment and Material Costs Item Qty Component description Cost Total Notes/Includes: 2 3 motor $3,096.00 $9,288.00 information. 3 1 Baldor-spare 20HP RPM AC ZDFRPM21204C motor $3,096.00 *Shipping: *$243.37 $3,339.38 Spare drive system motor, special pricing when purchased as a package, for more information. 4 1 Baldor-spare ZD22H425EL motor controller $8,660.00 *Shipping: *$243 37 $8,903.38 Spare drive system motor controller, special pricing when purchased as a package, for more information. $243.37 5 1 Baldor applications engineer for drive commissioning $5000.00 $5000.00 Plus travel expenses, i.e. airfare, lodging, rental car. 6 1 HFB3150-R, 150amp 600 volt 3 pole circuit breaker $650.00 *Shipping: *$69.45 $719.45 Southland Electrical Supply, for more information 7 1 Gexpro-Electrical conduit and wiring upgrades $3,868.84 $3,868.84 New 1awg wiring and conduit run from the 4th floor to the 5th floor, 8 gauge wire and conduit for the motor power runs, for more information 8 4 Parker Hannifin Pneumatic actuators for the dome drive frames $623.67 $2,530.68 Includes: four (4) Pneumatic actuators, (1) one is a spare, for more cost information. Parker Hannifin Female Rod clevis brackets for the dome $50 95 $203 80 Includes: Four (4) Female rod clevis, (1) one is a spare, for more cost information 10 4 Female Rod clevis brackets for the dome drive frames $50.95 $203.80 information. 11 4 Parker Hannifin Pivot pins for the dome drive frames $21.85 $87.40 Includes: four (4) Pivot pins, (1) one is a spare, for more cost information. 12 4 Pneumatic Solenoid valves, air lines, and fittings $655.00 $2,620.00 Includes: four (4) Solenoid valves, (1) one spare, for more cost information. Brevini $606 70 $ 2 426 80 Includes (4) motor adapter kits, (1) one spare kit, for more cost 13 4 Motor adapter kits-qty 4 $606.70 $ 2,426.80 ( ) p , ( ) p , information. 14 1 Heat mitigation

• Option1: Vent cabinet into the visitors

gallery

• Option 2: Fan above the stair access

door O ti 3 H t h ith l l $1,500.00 $1,500.00

• This is the cost for the third option in the heat mitigation.
• The second option will cost around $600.00
• Option 1 has no added costs
• Option 3:Heat exchanger with glycol

lines and fittings Misc materials and supplies $1,000.00 TOTAL $85,348.26

Appendix T OAP Dome Drive DDR Presentation T33

Any Additional Questions or Comments?

? QUESTIONS, COMMENTS?

Thank you for your time!

Appendix T OAP Dome Drive DDR Presentation T34